Instrument interface of a robotic surgical system

ABSTRACT

An instrument interface of a robotic manipulator and a surgical system including the instrument interface are provided. In one embodiment, the instrument interface includes a spring-loaded input for providing axial load and torque to a sterile adaptor capable of operably coupling an instrument. In another embodiment, a robotic surgical manipulator system includes a manipulator assembly, including a base link operably coupled to a distal end of a manipulator arm, and a carriage link movably coupled to the base link along a lengthwise axis, the carriage link including an integrated instrument interface. The system further includes an instrument operably coupled to the carriage link via the instrument interface, and a processor operably coupled to the manipulator assembly for sensing presence of the instrument.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims the benefit of U.S. Provisional Application No.60/752,755, filed Dec. 20, 2005, the full disclosure of which (includingall references incorporated by reference therein) is incorporated byreference herein for all purposes.

This application is a continuation-in-part of pending U.S. patentapplication Ser. No. 11/314,040, filed Dec. 20, 2005, entitled “SterileSurgical Adaptor”, which is a continuation-in-part of pending U.S.patent application Ser. No. 10/922,346, filed Aug. 19, 2004, which is acontinuation of U.S. patent application Ser. No. 10/004,399, filed Oct.30, 2001, which is a continuation of U.S. patent application Ser. No.09/406,360, filed Sep. 28, 1999, now U.S. Pat. No. 6,346,072, which is acontinuation of U.S. patent application Ser. No. 08/975,617, filed Nov.21, 1997, now U.S. Pat. No. 6,132,368, which claimed priority to U.S.Provisional Application No. 60/033,321, filed Dec. 12, 1996, the fulldisclosures of which are hereby incorporated by reference for allpurposes.

This application is related to U.S. application Ser. No. ______(Attorney Docket No. M-16315-1 US), filed Dec. 20, 2006, entitled “CableTensioning In A Robotic Surgical System”, U.S. application Ser. No.______ (Attorney Docket No. M-16315-2 US), filed Dec. 20, 2006, entitled“Telescoping Insertion Axis Of A Robotic Surgical System”, U.S.application Ser. No. 11/556,484, filed Nov. 3, 2006, entitled “IndicatorFor Tool State and Communication In a Multi-Arm Robotic Telesurgery”,U.S. application Ser. No. ______ (Attorney Docket No. M-16315-5 US),filed Dec. 20, 2006, entitled “Wireless Communication In A RoboticSurgical System”, and U.S. application Ser. No. 11/395,418, filed Mar.31, 2006, entitled “Sterile Surgical Adaptor”, the full disclosures ofwhich (including all references incorporated by reference therein) areincorporated by reference herein for all purposes.

TECHNICAL FIELD

The present invention is generally related to medical and/or roboticdevices, systems, and methods.

BACKGROUND

Minimally invasive medical techniques are intended to reduce the amountof extraneous tissue that is damaged during diagnostic or surgicalprocedures, thereby reducing patient recovery time, discomfort, anddeleterious side effects. One effect of minimally invasive surgery, forexample, may be reduced post-operative hospital recovery times. Becausethe average hospital stay for a standard surgery is typicallysignificantly longer than the average stay for an analogous minimallyinvasive surgery, increased use of minimally invasive techniques couldsave millions of dollars in hospital costs each year. While many of thesurgeries performed each year in the United States could potentially beperformed in a minimally invasive manner, only a portion of the currentsurgeries use these advantageous techniques due to limitations inminimally invasive surgical instruments and the additional surgicaltraining involved in mastering them.

Minimally invasive robotic surgical or telesurgical systems have beendeveloped to increase a surgeon's dexterity and to avoid some of thelimitations on traditional minimally invasive techniques. Intelesurgery, the surgeon uses some form of remote control, e.g., aservomechanism or the like, to manipulate surgical instrument movements,rather than directly holding and moving the instruments by hand. Intelesurgery systems, the surgeon can be provided with an image of thesurgical site at the surgical workstation. While viewing a two or threedimensional image of the surgical site on a display, the surgeonperforms the surgical procedures on the patient by manipulating mastercontrol devices, which in turn control motion of the servomechanicallyoperated instruments.

In robotically-assisted surgery, the surgeon typically operates a mastercontroller to control the motion of surgical instruments at the surgicalsite from a location that may be remote from the patient (e.g., acrossthe operating room, in a different room, or a completely differentbuilding from the patient). The master controller usually includes oneor more hand input devices, such as hand-held wrist gimbals, joysticks,exoskeletal gloves or the like, which are operatively coupled to thesurgical instruments that are releasably coupled to a patient sidesurgical manipulator (“the slave”). The master controller controls theinstruments' position, orientation, and articulation at the surgicalsite. The slave is an electro-mechanical assembly which includes aplurality of arms, joints, linkages, servo motors, etc. that areconnected together to support and control the surgical instruments. In asurgical procedure, the surgical instruments (including an endoscope)may be introduced directly into an open surgical site or more typicallythrough trocar sleeves into a body cavity. Depending on a surgicalprocedure, there are available a variety of surgical instruments, suchas tissue graspers, needle drivers, electrosurgical cautery probes,etc., to perform various functions for the surgeon, e.g., holding ordriving a needle, suturing, grasping a blood vessel, or dissecting,cauterizing or coagulating tissue.

A surgical manipulator assembly may be said to be divided into threemain components that include a non-sterile drive and control component,a sterilizable end effector or surgical tool/instrument, and anintermediate connector component. The intermediate connector componentincludes mechanical elements for coupling the surgical tool with thedrive and control component, and for transferring motion from the drivecomponent to the surgical tool.

A challenge with telerobotic surgery systems is that a surgeon willtypically employ a large number of different surgical instruments/toolsduring a procedure. Since the number of manipulator arms is limited dueto space constraints and cost, many of these surgical instruments willbe attached and detached from the manipulator arm a number of timesduring an operation.

While telesurgical systems, devices, and methods have proven highlyeffective and advantageous, still further improvements would bedesirable. In general, it would be desirable to provide an improvedinstrument interface on the manipulator arm to minimize instrumentexchange time and difficulty during the surgical procedure.

SUMMARY

In accordance with an embodiment of the present invention, an instrumentinterface of a robotic manipulator is provided, the instrument interfaceincluding a spring-loaded input for providing axial load and torque to asterile adaptor capable of operably coupling an instrument. Theinstrument interface may further include a spring plunger and aspring-loaded release lever.

In accordance with another embodiment of the present invention, arobotic surgical manipulator system is provided, the system comprising amanipulator assembly, including a base link operably coupled to a distalend of a manipulator arm, and a carriage link movably coupled to thebase link along a lengthwise axis, the carriage link including aninstrument interface as described above. The system further includes aninstrument operably coupled to the carriage link via the instrumentinterface, and a processor operably coupled to the manipulator assemblyfor sensing the instrument and/or sterile adaptor.

Advantageously, the present invention provides for simple and efficientinstallment and/or engagement of an instrument sterile adaptor (ISA)while enabling a cost-effective and disposable design for the ISA and asterile barrier. Other advantages of the invention are provided.

The scope of the invention is defined by the claims, which areincorporated into this section by reference. A more completeunderstanding of embodiments of the present invention will be affordedto those skilled in the art, as well as a realization of additionaladvantages thereof, by a consideration of the following detaileddescription of one or more embodiments. Reference will be made to theappended sheets of drawings that will first be described briefly.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a schematic plan view of a portion of an operating theaterillustrating a robotic surgical system, including a master surgeonconsole or workstation for inputting a surgical procedure and a roboticmanipulator system for robotically moving surgical instruments at asurgical site within a patient.

FIGS. 2A and 2B illustrate a perspective view and a front view,respectively, of an embodiment of a manipulator system, includingpositioning linkages or set up joints which allow a patient side roboticmanipulator and/or an endoscope or camera robotic manipulator to bepre-configured for surgery.

FIG. 3 is a perspective view of an example of a surgical instrument foruse in the system of FIG. 1.

FIG. 4 is a perspective from above of an alternative manipulator systemincluding a plurality of positioning linkages, each supporting amanipulator arm.

FIGS. 5A-5E and 5B1-5E1 are perspective views and respective side viewsof a manipulator including a telescopic insertion axis in accordancewith an embodiment of the present invention.

FIGS. 6A-6E illustrate different views of instrument interfacecomponents of the carriage link in accordance with an embodiment of thepresent invention.

FIGS. 7A-7D illustrate different views of the interior of the carriagelink in accordance with an embodiment of the present invention.

FIGS. 8A-8B illustrate the movement of a sterile adaptor engagementlever in accordance with an embodiment of the present invention.

FIGS. 9A-9E are different views of an instrument input in isolation inaccordance with an embodiment of the present invention.

FIGS. 10A-10B are cross-sectional views of the instrument input inaccordance with an embodiment of the present invention.

FIGS. 11A-11B are side views of the spring plungers in accordance withan embodiment of the present invention.

FIGS. 12A-12C illustrate a top perspective view, a bottom perspectiveview, and a sectional view, respectively, of a sterile adaptor, inaccordance with an embodiment of the present invention.

FIG. 13 illustrates a close up section view of an electrical contact ofthe sterile adaptor in accordance with an embodiment of the presentinvention.

FIGS. 14A and 14B illustrate close up perspective top and bottom viewsof a disc of the sterile adaptor, respectively, in accordance with anembodiment of the present invention.

FIGS. 15A and 15B illustrate top and bottom perspective views of a topretractor plate of the sterile adaptor in accordance with an embodimentof the present invention.

FIGS. 16A-16F show installation/engagement of the sterile adaptor to theinstrument interface, installation/engagement of the surgical instrumentto the sterile adaptor, and removal of the surgical instrument from thesterile adaptor in accordance with an embodiment of the presentinvention.

Embodiments of the present invention and their advantages are bestunderstood by referring to the detailed description that follows. Itshould be appreciated that like reference numerals are used to identifylike elements illustrated in one or more of the figures. It should alsobe appreciated that the figures may not be necessarily drawn to scale.

DETAILED DESCRIPTION

The present invention generally provides an improved robotic insertionaxis, system, and method for inserting an instrument, and in particularincludes a telescopic insertion axis for providing greater stiffness andstrength, a larger range of motion, and improved visibility of thesurgical field.

The present invention is particularly useful as part of a teleroboticsurgical system that allows the surgeon to manipulate the surgicalinstruments through a servomechanism at a location remote from thepatient. One example of a robotic surgical system is the da Vinci® S™surgical system available from Intuitive Surgical, Inc. of Sunnyvale,Calif. A User's Guide for the da Vinci® S™ surgical system is availablefrom Intuitive Surgical, Inc. and is incorporated by reference hereinfor all purposes.

FIGS. 1-3 illustrate components of a robotic surgical system 1 forperforming minimally invasive robotic surgery. System 1 is similar tothat described in more detail in U.S. Pat. No. 6,246,200, the fulldisclosure of which is incorporated herein by reference. A systemoperator O (generally a surgeon) performs a minimally invasive surgicalprocedure on a patient P lying on an operating table T. The systemoperator O sees images presented by display 12 and manipulates one ormore input devices or masters 2 at a surgeon's console 3. In response tothe surgeon's input commands, a computer processor 4 of console 3directs movement of surgical instruments or tools 5, effectingservomechanical movement of the instruments via a robotic patient-sidemanipulator system 6 (a cart-based system in this example) includingjoints, linkages, and manipulator arms each having a telescopicinsertion axis. In one embodiment, processor 4 correlates the movementof the end effectors of tools 5 so that the motions of the end effectorsfollow the movements of the input devices in the hands of the systemoperator O.

Processor 4 will typically include data processing hardware andsoftware, with the software typically comprising machine-readable code.The machine-readable code will embody software programming instructionsto implement some or all of the methods described herein. Whileprocessor 4 is shown as a single block in the simplified schematic ofFIG. 1, the processor may comprise a number of data processing circuits,with at least a portion of the processing optionally being performedadjacent an input device, a portion being performed adjacent amanipulator, and the like. Any of a wide variety of centralized ordistributed data processing architectures may be employed. Similarly,the programming code may be implemented as a number of separate programsor subroutines, or may be integrated into a number of other aspects ofthe robotic systems described herein.

In one example, manipulator system 6 includes at least four roboticmanipulator assemblies. Three linkages 7 (mounted at the sides of thecart in this example) support and position manipulators 8 with linkages7 in general supporting a base of the manipulators 8 at a fixed locationduring at least a portion of the surgical procedure. Manipulators 8 movesurgical tools 5 for robotic manipulation of tissues. One additionallinkage 9 (mounted at the center of the cart in this example) supportsand positions manipulator 10 which controls the motion of anendoscope/camera probe 11 to capture an image (preferably stereoscopic)of the internal surgical site. The fixable portion of positioninglinkages 7, 9 of the patient-side system is sometimes referred to hereinas a “set-up arm”.

In one example, the image of the internal surgical site is shown tooperator O by a stereoscopic display 12 in surgeon's console 3. Theinternal surgical site is simultaneously shown to assistant A by anassistance display 14.

Assistant A assists in pre-positioning manipulator assemblies 8 and 10relative to patient P using set-up linkage arms 7, 9; in swapping tools5 from one or more of the surgical manipulators for alternative surgicaltools or instruments 5′; in operating related non-robotic medicalinstruments and equipment; in manually moving a manipulator assembly sothat the associated tool accesses the internal surgical site through adifferent aperture, and the like.

In general terms, the linkages 7, 9 are used primarily during set-up ofpatient-side system 6, and typically remain in a fixed configurationduring at least a portion of a surgical procedure. Manipulators 8, 10each comprise a driven linkage which is actively articulated under thedirection of surgeon's console 3. Although one or more of the joints ofthe set-up arm may optionally be driven and robotically controlled, atleast some of the set-up arm joints may be configured for manualpositioning by assistant A.

Some of the manipulators include a telescopic insertion axis 100 inaccordance with an embodiment of the present invention, although inother embodiments, all of the manipulators may include a telescopicinsertion axis 100. Telescopic insertion axis 100 allows for movement ofmounted instrument 5, via three operably coupled links, with improvedstiffness and strength compared to previous designs, a larger range ofmotion, and improved dynamic performance and visibility proximate thesurgical field for system users (in addition to other advantages), as isdescribed in greater detail below.

For convenience, a manipulator such as manipulator 8 that is supportinga surgical tool used to manipulate tissues is sometimes referred to as apatient-side manipulator (PSM), while a manipulator 10 which controls animage capture or data acquisition device such as endoscope 11 may bereferred to as an endoscope-camera manipulator (ECM). The manipulatorsmay optionally actuate, maneuver and control a wide variety ofinstruments or tools, image capture devices, and the like which areuseful for surgery.

Instruments 5 and endoscope 11 may be manually positioned when settingup for a surgical procedure, when reconfiguring the manipulator system 6for a different phase of a surgical procedure, when removing andreplacing an instrument with an alternate instrument 5′, and the like.During such manual reconfiguring of the manipulator assembly byassistant A, the manipulator assembly may be placed in a different modethan is used during master/slave telesurgery, with the manuallyrepositionable mode sometimes being referred to as a clutch mode. Themanipulator assembly may change between the tissue manipulation mode andthe clutch mode in response to an input such as pushing a button orswitch on manipulator 8 (e.g., a clutch button/switch 103 in FIGS.6A-6C), or some other component to the manipulator assembly, therebyallowing assistant A to change the manipulator mode.

As can be seen in FIGS. 1 and 2A-2B, indicators 20 may be disposed on amanipulator assembly. In this embodiment, indicators 20 are disposed onmanipulators 8 near the interface between the manipulators and theirmounted tools 5. In alternative embodiments, indicators 20 may insteadbe disposed on set-up joints 7, 9, on tools 5, elsewhere on manipulators8, 10, or the like. An example of an indicator is disclosed in U.S.application Ser. No. 11/556,484, filed Nov. 3, 2006, the full disclosureof which (including all references incorporated by reference therein) isincorporated by reference herein for all purposes.

FIG. 3 illustrates a perspective view of an articulated surgical tool orinstrument 5. Tool 5 has a proximal housing 24 which interfaces with atool holder or instrument interface of the manipulator, generallyproviding a quick release mounting engagement through a sterile adapteror interface, an example of which is disclosed in U.S. patentapplication Ser. No. 11/314,040, filed Dec. 20, 2005, and U.S. patentapplication Ser. No. 11/395,418, filed Mar. 31, 2006, which areincorporated by reference herein for all purposes. Tool 5 includes anelongated shaft 23 supporting an end effector 28 relative to proximalhousing 24. Proximal housing 24 accepts and transmits drive signals anddrive motion between the manipulator 8 and the end effector 28. Anarticulated wrist 29 may provide two degrees of freedom of motionbetween end effector 28 and shaft 23, and the shaft may be rotatablerelative to proximal housing 24 about the axis of the shaft so as toprovide the end effector 28 with three orientational degrees of freedomwithin the patient's body.

The surgical tool may include a variety of articulated end effectors,such as jaws, scissors, graspers, needle holders, micro-dissectors,staple appliers, tackers, suction irrigation tools, and clip appliers,that may be driven by wire links, eccentric cams, push-rods, or othermechanisms. In addition, the surgical tool may comprise anon-articulated instrument, such as cutting blades, probes, irrigators,catheters or suction orifices. Alternatively, the surgical tool maycomprise an electrosurgical probe for ablating, resecting, cutting orcoagulating tissue. Examples of applicable adaptors, tools orinstruments, and accessories are described in U.S. Pat. Nos. 6,331,181,6,491,701, and 6,770,081, the full disclosures of which (includingdisclosures incorporated by reference therein) are incorporated byreference herein for all purposes. Applicable surgical instruments arealso commercially available from Intuitive Surgical, Inc. of Sunnyvale,Calif.

Referring now to FIG. 4, a perspective view is illustrated of analternative modular manipulator support assembly 30 that may be mountedto a ceiling of an operating room. The modular manipulator support 30aligns and supports a robotic manipulator system relative to a set ofdesired surgical incision sites in a patient's body. Modular manipulatorsupport 30 generally includes an orientating platform 36 and a pluralityof configurable set-up linkage arms 38, 40, 42, 44 that may be coupledto the orienting platform. Each arm movably supports an associatedmanipulator 32, 34, which in turn movably supports an associated tool oran image capture device. Orienting platform 36 also supports anassistant display 104, which may be used for set-up, instrument changes,viewing of the procedure, and the like. The structures and use of any ofthe components of modular manipulator support assembly 30 are analogousto those described above regarding manipulator system 6, and are morefully described in co-pending U.S. patent application Ser. No.11/043,688, filed on Jan. 24, 2005, and entitled “Modular ManipulatorSupport For Robotic Surgery”, the full disclosure of which isincorporated herein by reference. As generally described above, eachmanipulator 32, 34 of modular manipulator support 30 may also include aninsertion axis 100.

Referring now to FIGS. 5A-5E1, manipulator 8 including a telescopicinsertion axis 100 is shown in more detail in accordance withembodiments of the present invention. The insertion axis of the presentinvention is comprised of a three-stage telescopic linear axis includingthree links, in one example, movably coupled to one another viabearings, rails, pulleys, and cables, with the links narrowing in widthor form factor moving from the proximal link toward the distal link.Advantageously, the present invention provides for one-handed port andone-handed instrument clutching, a larger range of motion, a narrowerinsertion arm, and greater insertion axis stiffness and strength withreduced inertia as a function of insertion depth, thereby helping toenable a two-quadrant surgery with a single setup (e.g., a colorectalsurgery), and providing for more space and visibility near the surgicalfield.

FIGS. 5A-5E and 5B1-5E1 illustrate perspective views and respective sideviews of manipulator 8 including a manipulator arm 50, and telescopicinsertion axis 100 operably coupled to a distal end of arm 50 inaccordance with an embodiment of the present invention. Telescopicinsertion axis 100 includes a first link or base link 102, a second linkor idler link 104 operably coupled to base link 102, and a third link orcarriage link 106 operably coupled to idler link 104.

Base link 102 is operably coupled to a distal end of manipulator arm 50,and in one example has an accessory clamp 108 attached to a distal endof base link 102. An accessory 110, such as a cannula, may be mountedonto accessory clamp 108. An example of applicable accessory clamps andaccessories are disclosed in pending U.S. application Ser. No.11/240,087, filed Sep. 30, 2005, the full disclosure of which isincorporated by reference herein for all purposes. An example ofapplicable sterile adaptors and instrument housings are disclosed inU.S. application Ser. No. 11/314,040, filed Dec. 20, 2005 and in U.S.application Ser. No. 11/395,418, filed Mar. 31, 2006, the fulldisclosures of which are incorporated by reference herein for allpurposes.

Carriage link 106 includes an instrument interface 101 for operablycoupling to an instrument sterile adaptor (ISA) 109, which is capable ofoperably coupling to a housing of an instrument (e.g., housing 24 ofFIGS. 3 and 5), and controls the depth of the instrument inside apatient. In one embodiment, the sterile adaptor is integrated with adrape that may be draped over the robotic surgical system, and inparticular the manipulator system, to establish a sterile barrierbetween the non-sterile PSM arms and the sterile field of the surgicalprocedure. An example of an applicable drape and adaptor is disclosed inpending U.S. application Ser. No. 11/240,113, filed Sep. 30, 2005, thefull disclosure of which is incorporated by reference herein for allpurposes.

Idler link 104 is movably coupled between base link 102 and carriagelink 106 to allow the links 102, 104, and 106 to move relative to oneanother along a lengthwise axis (e.g., axis C) in a telescoping fashion.In one embodiment, link 102 has a narrower form factor than link 104,and link 104 has a narrower form factor than link 106, thus providingfor greater visibility near the surgical field.

Motion along axes C through G in manipulator 8, as shown in FIGS. 5A and5A1, are provided by cables extending at least between the proximal anddistal links in accordance with the present invention. The robotic armcan then control a tool or instrument operably coupled to the arm. Thecables are a component of a transmission system also including drivepulleys, capstans, idler pulleys, and/or output pulleys, which aredriven by electric motors. A pulley bank is located on an underside ofbase link 102 for passing cables and electrical wires between insertionaxis 100 and manipulator arm 50 of manipulator system 6. A plurality ofmotion feed-throughs, in addition to other elements, may also beprovided for transferring motion.

The drive assembly may further include a plurality of drive motorscoupled to the arm for rotation therewith. Yaw and pitch motors controlthe motion of the arm about the A axis and the B axis (FIG. 5A),respectively, and drive motors control the motion of the wrist unit andinsertion position. In one embodiment, four drive motors are mountedproximally in the arm to control four degrees of freedom of the toolmounted distally on the arm (the D, E, F, and G axes). Also, aproximally mounted motor controls the insertion position of the tooldistally on the arm (along the C axis). The drive motors will preferablybe coupled to encoders and potentiometers (not shown) to enable theservomechanism. Embodiments of the drive assembly, arm, and otherapplicable parts are described for example in U.S. Pat. Nos. 6,331,181,6,491,701, and 6,770,081, the full disclosures of which (includingdisclosures incorporated by reference therein) are incorporated hereinby reference for all purposes. The manipulator arm and the driveassembly may also be used with a broad range of positioning devices. Amore complete description of a remote center positioning device can befound in U.S. patent application Ser. No. 08/504,301, filed Jul. 20,1995, now U.S. Pat. No. 5,931,832, the complete disclosure of which isincorporated herein by reference for all purposes.

Referring now to FIGS. 6A-6E, a perspective view of an instrumentinterface 101 of a carriage link 106 for receiving an instrument sterileadaptor and ultimately an instrument (e.g., instrument 5) is illustratedin accordance with an embodiment of the present invention. Instrumentinterface 101 includes a shroud 502 to isolate electrical contacts 510(e.g., from accidental contact), a spring-loaded input 504 for providingpreload to ISA discs, each input having bosses 505 for delivering torqueto the surgical instrument, a spring plunger 506 for providing preloadto the ISA's retractor plate, a bracket 508 to hold ISA 109 in place, alever 511 for securing/releasing the ISA, and a fiducial 512 also usedto fix the position of the sterile adaptor relative to the roboticmanipulator. In one example, instrument interface 101 includes fourspring loaded inputs 504 with each input having two bosses 505, fourspring plungers 506, and seven electrical contacts 510.

Referring now to FIGS. 7A-7D, the carriage link is illustrated with aninstrument interface cover 101 a separated from a remaining portion ofthe carriage link in accordance with an embodiment of the presentinvention. The present invention provides a compact apparatus and methodto efficiently package the instrument interface components on the outputend of a surgical robot. These components include but are not limited tocircuit boards, cable transmission elements, sensors, and levers. FIG.7A illustrates instrument interface cover 101 a and the interiorinstrument interface components 101 b of carriage link 106. Cover 101 aincludes fiducial 512, shroud 502 including openings 522 for electricalcontacts 510, mounting bracket 508, an opening 520 for the lever 511,openings 524 for spring plungers 506, and openings 526 for spring loadedinputs 504. This “clamshell” or cover design for the instrumentinterface allows for easy access to the internal mechanisms, circuitboards, and cable transmission elements of the insertion axis whennecessary.

FIGS. 7A-7C also illustrate electrical contacts 510 and a Hall-effectsensor 514 operably mounted to a printed circuit assembly (PCA) 516.Electrical contacts 510 provide the interface to pass electrical signalsbetween the ISA 109 and the PCA, and in one example may include “pogopins”. In one embodiment, the remote PCA 516 may have inputs and outputsfor providing power and/or communicating with LEDs, Hall effect sensors,a sterile adaptor, an instrument, and a user interface button (e.g., fora clutch operation). The remote PCA 516 may also include an input forreceiving power and an input/output for communicating with a main PCA(e.g., processor 4 of FIG. 1). In one embodiment, the main PCA may haveinputs and outputs for providing power and/or communicating with motors(e.g., the main PCA transmits position controls to the motors andprocesses potentiometer and encoder signals), sensors, the userinterface button, the remote PCA, and other printed circuit boards on apatient side cart system via a serial communication bus. An example ofthe inputs and outputs of applicable PCAs are described in U.S.application Ser. No. ______ (Attorney Docket No. M-16315-5 US), filedDec. 20, 2006, entitled “Wireless Communication In A Robotic SurgicalSystem”, the complete disclosure of which has been previouslyincorporated herein by reference for all purposes. The remote PCA mayinclude, in one example, an Embedded Serializer for Instrument Interface(ESII) PCA, and the main PCA may include, in one example, an EmbeddedSerializer Patient Manipulator (ESPM) PCA, both available from IntuitiveSurgical, Inc. of Sunnyvale, Calif.

Hall-effect sensor 514 is used to provide a robust means and method todetect the presence of an instrument mounted on ISA 109. Hall-effectsensors are desirable because they are solid-state devices with nomoving parts. FIGS. 7A and 7C illustrate Hall-effect sensors 514 withouta protective cover, and FIG. 7B illustrates a side view of theHall-effect sensors 514 with a protective cover. In one embodiment, twoadjacent Hall-effect sensors may be used to change state in the presenceof a magnet in the instrument chassis. When the instrument magnet comeswithin close proximity to the Hall-effect sensors, the electrical outputstate of the sensors changes. PCA 516 detects the change in state of thesensors and notifies the system that an instrument is mounted. PCA 516may also be able to detect the presence of other system components, suchas an ISA or an instrument, via presence detection circuitry.

In another example, in addition to the Hall-effect sensors, a thirdinput may be required for the system to recognize an instrument ismounted. The output of Hall-effect sensors 514 may be used inconjunction with an electrical circuit (e.g., a loopback circuit) thatcloses in the presence of the instrument thereby providing redundantpresence confirmation. PCA 516 detects the closing of this circuit aswell. FIG. 7D illustrates lever 511 for securing/releasing the ISA.Lever 511 includes a lever body 511 a and mountings screws 511 b formounting a shaft 511 c about which lever body 511 a may rotate. Atorsion spring 511 e and hard stop 511 d operate to place lever body 511a in a rest “up” position when the ISA is mounted and in a rotatedposition when the ISA is being installed or removed. Lever body 511 amay rotate downward by approximately 25 degrees from a horizontal line.FIGS. 8A and 8B illustrate lever 511 in the rest position and in arotated position, respectively.

FIGS. 9A-9E are different views of an instrument input 504 in isolation,and FIGS. 10A-10B are cross-sectional views of the instrument input inaccordance with an embodiment of the present invention. FIGS. 9A, 9B,and 9D illustrate input 504 in a rest (extended) position and FIGS. 9Cand 9E illustrate input 504 in a retracted position. Input 504 includesa spring 504 a, radial ball bearings 504 b, an output pulley 504 c, alinear ball spline slide unit 504 d, a ball spline shaft 504 e, a screw504 f, and an input bar 504 g including bosses 505. Other means may alsobe used to achieve linear motion and torque transfer, such as linearslides, v-rollers, sliding bushings, ball screws, etc.

Spring 504 a provides a spring force in the axial direction of shaft 504e (an axial load) (shown by the double sided arrow in FIG. 9D), therebyallowing the input bar 504 g to linearly translate in the axialdirection. Radial ball bearings 504 b enable the rotational motion ofthe assembly about the longitudinal (or lengthwise) axis of shaft 504 e,and ball spline slide unit 504 d supports the rotational motion of theassembly, in particular the rotational motion of shaft 504 e andtherefore input bar 504 g, which allows for the transfer of torque fromoutput pulley 504 c to the instrument via ISA discs 304 (FIG. 12A). Inone example, ball spline slide unit 504 d is clamped to the outputpulley and includes two tracks of recirculating balls which serve as therolling elements in the direction of motion of the spline shaft 504 e.Output pulley 504 c is driven by cables, as disclosed in U.S.application Ser. No. ______ (Attorney Docket No. M-16315-1 US), filedDec. 20, 2006, entitled “Cable Tensioning In A Robotic Surgical System”,the full disclosure of which (including all references incorporated byreference therein) has been previously incorporated by reference hereinfor all purposes. In one example, spline shaft 504 e includes twogrooves along its length that the recirculating balls ride in. Screw 504f is threaded into spline shaft 504 e to provide a hard stop in theaxial direction. Input bar 504 g is pressed onto spline shaft 504 e, inone example, and provides bosses 505 that engage into holes in thesterile adaptor discs.

FIGS. 11A-11B are side views of the spring plungers in accordance withan embodiment of the present invention. FIG. 11B illustrates springplungers 506 in a rest (extended) position and FIG. 11C illustratesspring plungers 506 in a retracted position when providing a biasagainst a retractor plate of ISA 109.

The spring-loaded inputs 504, spring plungers 506, and lever 511 providespring elements on the manipulator, thereby allowing for a disposabledesign for the ISA and sterile barrier. Advantageously, the manipulatorand ISA installment and engagement is easier to use, more reliable andrequires less effort while enabling a cost-effective and disposabledesign for the ISA and a sterile barrier drape.

Referring now to FIGS. 12A, 12B, and 12C, a top perspective view, abottom perspective view, and a sectional view of ISA 109, respectively,are illustrated in accordance with an embodiment of the presentinvention. ISA 109 includes a housing 302, a disc 304, a top retractorplate 306, an instrument stop feature 308 of housing 302, a rail feature301 of housing 302, a contact 310, and a bottom retractor plate 312. Topretractor plate 306 and bottom retractor plate 312 form a retractorplate assembly 313 which moves relative to housing 302. Discs 304 arecaptured inside of retractor plate assembly 313 and move relative to theretractor plate assembly.

FIG. 13 illustrates a close up sectional view of a contact 310, which isinsert molded into the housing in one embodiment.

FIGS. 14A and 14B illustrate close up perspective top and bottom viewsof disc 304, respectively, which includes a tooth 314 at the base ofdisc 304, a hole 316 in the body of disc 304 for accepting pins 253 of asurgical instrument 5 (see FIGS. 16D and 16E), a hole 317 in the bottomof disc 304 for receiving bosses 505 of spring loaded inputs 504 (seeFIGS. 9 and 10), and a tab 315 for moving disc 304 out of a dead zone,in accordance with an embodiment of the present invention. In thisembodiment ISA 109 includes four discs 304 with each disc 304 includingfour teeth 314 and two holes 316. The four teeth 314 are placed 90degrees apart in one embodiment. It is noted that in other embodiments,more or less discs, teeth, and slots are possible but need to operablycouple to an adaptor receiving portion on the manipulator and a surgicalinstrument.

FIGS. 15A and 15B illustrate top and bottom perspective views of topretractor plate 306 in accordance with an embodiment of the presentinvention. Top retractor plate 306 includes a bar 318 for engaging theinstrument chassis 24 and a tooth 319 for mating with a tooth 314 ofdisc 304 depending on relative position. As shown, top retractor plate306 includes four apertures 307 for the four discs 304.

Referring now to FIGS. 16A through 16F, installation/engagement of aninstrument sterile adaptor (ISA) 109 to instrument interface 101 (FIG.16A), installation/engagement of surgical instrument 5 to ISA 109 (FIGS.16B-16E), and removal of surgical instrument 5 from ISA 109 (FIG. 16F)are illustrated in accordance with an embodiment of the presentinvention.

FIG. 16A shows ISA 109 installed and engaged with adaptor receivingportion 101 of manipulator 8. ISA contacts 310 are coupled tomanipulator contacts 510, discs 304 are engaged with spring loadedinputs 504, bottom retractor plate 312 is engaged with spring plungers506, and tongue feature 305 (FIGS. 16A and 16F) mates with bracket 508.Instrument stop feature 308 allows for stopping of the instrument (forpatient safety) if the user misses the rails 301 when installing theinstrument onto the ISA. The instrument is fully stopped by bar 318 ontop retractor plate 306 when installed. Prior to installation, springloaded inputs 504 and spring plungers 506 are at their most extendedposition, and discs 304 of the ISA are free to rotate to any randomlocation within the retractor plate assembly. In one embodiment, toinstall ISA 109 onto the adaptor-receiving portion of interface 101, theuser places the tongue of the ISA housing into a bracket and swings theback end down thereby engaging a lever/latch 511.

In this installed but pre-engaged position, discs 304 are pressed upwardagainst top retractor plate 306 by spring loaded inputs 504, andretractor plate assembly 313 is pressed upward by spring loaded inputs504 and spring plungers 506. In each disc location (aperture 307 ofretractor plate 306), there is one tooth 319 on the retractor plate 306which engages with teeth 314 of disc 304. The teeth configuration hasmultiple functions, one of which is to push discs 304 out of a “deadzone” which is an angular orientation where the holes 317 in the bottomof disc 304 are in a position where they may not mate with bosses 505 ofspring loaded inputs 504 since they do not rotate through a full 360degrees. Another function of the teeth configuration is to prevent disc304 from rotating more than 90 degrees during the sterile adaptorengagement sequence.

During the engagement sequence, disc teeth 314 mesh with retractor plateteeth 319 as spring loaded inputs 504 are activated to impart movementof disc 304 through friction between bosses 505 and the bottom surfaceof disc 304 and through contact with tab 315. When the spring loadedinputs 504 reverse rotational direction, the presence of the four teeth314 stops this rotational motion of disc 304, and bosses 505 are allowedto line up with holes 317 of disc 304 as the spring loaded inputs 504rotate relative to disc 304. As holes 317 on the bottom of disc 304 andbosses 505 of spring loaded inputs 504 align, discs 304 drop onto springloaded inputs 504. At this point, the teeth 319 of top retractor plate306 clear the teeth 314 of disc 304 as disc 304 is dropped down, therebyallowing disc 304 to move freely relative to retractor plate 306. Whendiscs 304 are engaged onto spring loaded inputs 504, ISA 109 is engagedwith adaptor receiving portion 101.

In one embodiment, the engagement sequence happens in milliseconds afterinstallation of ISA 109 onto adaptor receiving portion 101. As ISA 109is swung down into position, electrical contacts 310 engage electricalcontacts 510 (e.g., pogo pins) such that an initially open circuit onthe manipulator 8 is closed, which activates the ISA engagementsequence. It is noted that the insert-molded contact 310 in housing 302may have multiple electrical paths (vias) which engage with contacts onthe adaptor receiving portion 101, and which are also used to establishcommunication with a surgical instrument 5 via instrument electricalcontacts 255 (FIGS. 16C and 16D).

FIG. 16B shows surgical instrument 5 partially installed, and FIG. 16Cshows surgical instrument 5 fully installed and engaged with ISA 109.Initially, as the user installs surgical instrument 5 onto ISA 109,retractor plate assembly 313 is pushed down toward adaptor receivingportion 101 as top retractor plate 306 is pressed down by instrument 5engaging center bar 318. Prior to electrical engagement betweeninstrument 5 and ISA 109, a chamfer on bar 318 engages a chamfer on thebottom of instrument 5, and as these two chamfers are aligned, theinstrument is pulled into its home position due to the spring force ofthe spring loaded inputs and spring plungers. As the instrument ispulled into its home position, retractor plate assembly 313 begins torise up into the surgical instrument, and in substantially the samemotion, the electrical contacts 255 of instrument 5 come into contactwith electrical contacts 310 of ISA 109. When instrument 5 is installedonto ISA 109, top retractor plate 306 is pressing on the bottom of theinstrument and bar 318 is inside a clearance slot in the instrumenthousing. Prior to instrument engagement, discs 304 and spring loadedinputs 504 are pressed away from the instrument since the inputs on theinstrument are not engaged with the holes 316 on the top of disc 304.

FIGS. 16D and 16E illustrate an engagement sequence of disc 304 withinstrument 5. In FIG. 16D, disc 304 is not engaged with instrument 5until disc 304 rotates to align with instrument disc 251, which isinitially in a random position. As previously mentioned with respect tothe engagement sequence between ISA 109 and adaptor receiving portion101, as the electrical contacts of the instrument engage the contacts310 of ISA 109, a normally open circuit between the ESII printed circuitboard and instrument, through the ISA, is closed which activates theinstrument engagement sequence. Spring loaded inputs 504 and discs 304rotate together as an assembly until the holes 316 of disc 304 engagewith the pins 253 of instrument disks 251. When the holes are alignedwith the pins, disc 304 and spring loaded inputs 504 are allowed to moveupwards. FIG. 16E shows instrument disk 251 having a pin 253 whichengages with hole 316 of ISA disk 304. At this point instrument 5 isconsidered engaged with ISA 109. It is noted that other contacts on ISA109 may transmit electrical signals between the surgical system and aninstrument “Reposable Tool Interface” (RTI) board.

When the instrument is fully installed, it is held in position at threepoints along its housing. Two points are at the rail features 301 alongthe sides of the instrument, and a third point is at the center holddown tab 309 along the front center of the instrument. Advantageously,by holding down the instrument at three locations, the instrument is notover-constrained and installation and removal is made easier.

FIG. 16F illustrates removal of instrument 5 (not shown) from ISA 109.When the user wants to remove the instrument, levers on either side ofthe instrument chassis are squeezed and the instrument is pulled backout of the ISA. The levers on the instrument act on the center bar 318of the top retractor plate, which in turn pushes the retractor platedown away from the instrument. As the retractor plate moves furtheraway, the discs 304 are disengaged from the pins of the instrumentallowing for removal of the instrument.

Embodiments described above illustrate but do not limit the invention.It should also be understood that numerous modifications and variationsare possible in accordance with the principles of the present invention.For example, the system is not limited to four robotic manipulatorassemblies, but may include two or more in other examples. Accordingly,the scope of the invention is defined only by the following claims.

1. An integrated instrument interface of a robotic manipulator,comprising: a spring-loaded input for providing axial load and torque toa sterile adaptor capable of operably coupling an instrument.
 2. Theinstrument interface of claim 1, wherein the spring-loaded inputincludes an input bar coupled to a shaft operably coupled to an outputpulley.
 3. The instrument interface of claim 2, wherein the input barincludes a boss for engaging the sterile adaptor.
 4. The instrumentinterface of claim 1, further comprising a plurality of spring-loadedinputs for operably engaging the sterile adaptor.
 5. The instrumentinterface of claim 1, further comprising a spring-loaded release leverfor attaching or releasing the sterile adaptor.
 6. The instrumentinterface of claim 5, wherein the release lever includes a torsionspring for biasing a lever body.
 7. The instrument interface of claim 1,further comprising a Hall-effect sensor for sensing presence of theinstrument.
 8. The instrument interface of claim 7, wherein theHall-effect sensor is capable of sensing a magnet mounted inside theinstrument.
 9. The instrument interface of claim 1, further comprising afiducial for fixing the position of the sterile adaptor relative to therobotic manipulator.
 10. The instrument interface of claim 1, furthercomprising a spring plunger for providing axial force against thesterile adaptor.
 11. The instrument interface of claim 1, furthercomprising a sterile adaptor mounting bracket.
 12. The instrumentinterface of claim 1, further comprising an electrical interface forinterfacing between the sterile adaptor and a printed circuit assembly.13. The instrument interface of claim 12, further comprising aprotective shroud surrounding the electrical interface.
 14. Theinstrument interface of claim 1, wherein the instrument is selected fromthe group consisting of jaws, scissors, graspers, needle holders,micro-dissectors, staple appliers, tackers, suction irrigation tools,clip appliers, cutting blades, cautery probes, irrigators, catheters,and suction orifices.
 15. A robotic surgical manipulator system,comprising: a manipulator assembly, including: a base link operablycoupled to a distal end of a manipulator arm; and a carriage linkmovably coupled to the base link along a lengthwise axis, the carriagelink including an integrated instrument interface having a spring-loadedinput for providing axial load and torque to a sterile adaptor capableof operably coupling an instrument; an instrument operably coupled tothe carriage link via the instrument interface; and a processor operablycoupled to the manipulator assembly for sensing presence of theinstrument.
 16. The system of claim 15, wherein the spring-loaded inputincludes an input bar coupled to a shaft operably coupled to an outputpulley.
 17. The system of claim 15, wherein the instrument interfacefurther includes a plurality of spring-loaded inputs for operablyengaging the sterile adaptor.
 18. The system of claim 15, wherein theinstrument interface further includes a Hall-effect sensor for sensingpresence of the instrument.
 19. The system of claim 18, wherein theHall-effect sensor is capable of sensing a magnet mounted inside theinstrument.
 20. The system of claim 15, wherein the instrument isselected from the group consisting of jaws, scissors, graspers, needleholders, micro-dissectors, staple appliers, tackers, suction irrigationtools, clip appliers, cutting blades, cautery probes, irrigators,catheters, and suction orifices.
 21. The system of claim 15, wherein thesterile adaptor is integrated with a sterile drape for separating a partof the robotic surgical system from a surgical field.
 22. The system ofclaim 15, wherein the instrument interface further includes aspring-loaded release lever for attaching or releasing the sterileadaptor.